Prediction of springback in multi-point forming

Elghawail, Ali; Essa, Khamis; Abosaf, Mohamed; Tolipov, Abror; Su, Shizhong; Pham, Duc Truong

doi:10.1080/23311916.2017.1400507

Cited by 12 publications

(18 citation statements)

References 18 publications

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“…In Figure 4, B 0 represents the length of the rectangular section before deformation, B represents the length of the rectangular section after deformation, H 0 represents the height of the rectangular section before deformation, and H represents the height of the rectangular section after deformation. (B − B 0 )/B indicates the bulging rate, and (H − H 0 )/H indicates the depression rate [17,18]. e variation of depression rate and bulging rate with the bending angle and the type of bulging rate has been studied [19].…”

Section: Study On the Section Distortion Of Rectangular Profiles Durimentioning

confidence: 99%

“…erefore, a large amount of waste parts may be processed, resulting in an increase in cost [14][15][16]. So, exploring the variation law of cross-section distortion of aluminum profiles during three-dimensional stretch-bending has certain guiding significance for actual production [17][18][19]. is paper investigates the influence of the bending angle of the profile on the cross-section distortion and the variation law.…”

Section: Introductionmentioning

confidence: 99%

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Study on the Influence of Bending Angle of Multipoint Stretch-Bending of Profiles on Section Distortion of Parts

Liang

Liao

2020

Mathematical Problems in Engineering

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The ABAQUS finite element simulation software was used to simulate the flexible 3D multipoint stretch-bending (MPSB) forming process of aluminum profiles. The influence of bending angle on the section distortion was investigated. The results show that the type of rectangular section distortion during horizontal bending and vertical bending is different. The bulging rate and the depression rate increase with the increase in horizontal bending angles; when the vertical bending angle is less than 15°, the depression rate of the horizontally curved section is effectively reduced. When α is equal to 30°, β is less than 15° which can effectively reduce the depression rate caused by horizontal bending to the profile. When α is less than 30°, the depression rate which is caused by horizontal bending can be reduced through the vertical bending angle, with 5° than 15°; the vertical bending process changes the distortion pattern of the profile; the depression rate and the bulging rate increase with the increase of the vertical bending angle. Through the support vector regression and selecting the parameter group c = 1.5, g = 0.05, the distortion rate of different angles in the common range is further expanded, and the quality control curve is drawn by combining the test results and prediction results which determine the depression rate as 2%, 2.5%, and 3% processing boundary. Using this curve to predict the distortion rate of the profile is instructive in the actual processing.

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Section: Study On the Section Distortion Of Rectangular Profiles Durimentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Study on the Influence of Bending Angle of Multipoint Stretch-Bending of Profiles on Section Distortion of Parts

Liang

Liao

2020

Mathematical Problems in Engineering

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“…Design of experiments (DoE) and analysis of variance (ANOVA) have been widely reported to be useful in studying the effect of process parameters on the process responses of many manufacturing industries [10][11][12][13] and in sheet forming [2,7]. The process parameters included in this work were the cushion thickness, the size of the cushion mesh and geometry of the mesh (circular and square).…”

Section: Optimisation Using Design Of Experimentsmentioning

confidence: 99%

“…Furthermore, in MPF, the metal sheet is subjected to a combination of stretching and elastic-plastic deformation. Springback of the sheet metal is caused by the recovery of the elastic deformation [7]. To reduce or eliminate wrinkling on the workpiece during MPF, the punch pressure must be higher than the compressive force induced from the sheet metal.…”

Section: Introductionmentioning

confidence: 99%

Multipoint forming using mesh-type elastic cushion: modelling and experimentation

Tolipov

Elghawail

Abosaf

et al. 2019

Int J Adv Manuf Technol

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There is a growing demand for flexible manufacturing techniques that meet the rapid changes in production technology, processes and innovations. Multipoint forming (MPF) is a flexible sheet metal forming technique where a reconfigurable die can be readily changed to produce various shapes. Parts produced using MPF suffer from geometrical defects such as wrinkling, dimpling and thickness variations. In this paper, a multipoint forming process using a novel mesh-type elastic cushion was proposed in order to improve the quality of the deformed sheet and to minimise the developed defects. Finite element modelling (FEM) and design of experiments (DoE) were used to study the influence of the mesh-type elastic cushion parameters such as the type and the size of the mesh, and the thickness of the cushion on the wrinkling, deviation and thickness variations of the deformed sheet. The results showed that using elastic cushion with square meshes of a size of 3.5 mm and a thickness of 3 mm reduced the wrinkling from 3.18 to 1.98 mm, while the thickness variation improved from 98 to 19 μm. Finally, the deviation from target shape reduced from 1.7848 to 0.0358 mm.

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“…Polyurethane A90, a hyper-elastic material, was adopted as the material for both the elastic punch and the elastic cushion in the simulation analysis. The Mooney-Rivlin materials model was chosen among three common models (Mooney-Rivlin, Yeoh and Neo Hook) according to evaluation results by ABAQUS to describe the relation between stress-strain of rubber material [1,6,8,15].…”

Section: Fe Modelling Of Ep-mpfmentioning

confidence: 99%

Low-cost metal-forming process using an elastic punch and a reconfigurable multi-pin die

et al. 2018

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Due to the need for low-cost tooling and quality parts, a new technique has been developed which brings together the benefits of both multi-point forming (MPF) and rubber-pad forming. A significant disadvantage of MPF is the time required to adjust the heights of the pins in the upper and lower matrices and align the tools. Rubber forming achieves flexibility by replacing one of the MPF pin matrices by an elastic punch. In this study, polyurethane (PU) rubber with a Shore hardness of A90 was adopted as the elastic punch material. The punch was combined with a reconfigurable MPF die to reduce both tool cost and time to set the pins to produce doubly curved parts of acceptable quality. Experimental work has been carried out to confirm the validity of the new technique. Finite element modelling (FEM) using the ABAQUS software was applied to study stress distribution numerically in the formed parts at the end of the forming process. The amounts of wrinkling and springback were employed as criteria to evaluate the quality of the formed part and to compare the results of the current (semi-MPF) approach against full-MPF results. The major outcomes of this study were time and cost reductions of at least 50% with the added benefits that there is a significant decrease in wrinkling and springback in the final formed part even without using a blank holder.

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Prediction of springback in multi-point forming

Cited by 12 publications

References 18 publications

Study on the Influence of Bending Angle of Multipoint Stretch-Bending of Profiles on Section Distortion of Parts

Study on the Influence of Bending Angle of Multipoint Stretch-Bending of Profiles on Section Distortion of Parts

Multipoint forming using mesh-type elastic cushion: modelling and experimentation

Low-cost metal-forming process using an elastic punch and a reconfigurable multi-pin die

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